Insulated Concrete Masonry System

ABSTRACT

An insulated masonry wall system comprised of special blocks of 24″×16″×8″ dimension filled with reclaimed rubber crumbs resulting in high R values to resist transmission of heat and cold. Insulation is blown and vibrated into the special concrete blocks as walls are developed. Construction of wall will be similar to standard masonry blocks. Facings attached to the blocks can be vinyl and wood siding, brick, stucco, textured acrylic finish, fiber-cement siding hardboard, photovoltaic siding, and wood shakes.

FIELD OF THE INVENTION

This patent relates to special concrete and other masonry blocks, walls,and other structures and more specially to structures that containinsulation.

BACKGROUND OF THE INVENTION

Masonry walls and similar structures have been made for many years ofblocks made of concrete and other materials. Also, masonry walls havebeen fabricated of poured concrete with and without steel reinforcementbar installations (FIGS. 12 and 13). The field of the invention pertainsto structural blocks such as those commonly referred to as “concreteblocks” used for constructing both load bearing and non-load bearingwalls of buildings. Such blocks are usually formed with two or threevertical cavities formed therein and made of concrete (FIG. 10). Thecavities in the blocks provide a substantial decrease in weight andmaterial without a commensurate decrease in structural strength. Thecavities also provide some insulating value as closed airspace in acompleted wall. U.S. Pat. Nos. 4,263,765, 4,286,420, and 4,348,845reflect this approach.

More recently however, attempts have been made to fill those cavitieswith different materials such as foams, fiberglass and rubber particlesto decrease the transfer of thermal convection within the cavities. U.S.Pat. Nos. 5,214,897, 5,507,127, and 5,746,037 address the use ofinsulation materials in blocks, specifically tire rubber (FIGS. 3 and11). These methods were at best marginal because the typical 16″×8″×8″cement block with its 8″ thickness, even blocks whose cavities arefilled with insulation, contribute limited resistance to thetransmission of heat and cold in the wall assembly.

Also, when introduced, the blocks were a new approach to wallconstruction (FIG. 2) and where workmen were not trained to use them,the resulting block walls were often of poor quality. Many years later,concrete block walls are considered ubiquitous and workmen are familiarwith their use. Since our larger block design (24″×16″×8″) builds onexisting wall construction methodology, little re-training is needed.Consequently, the quality of walls made with the special blocks shouldbe comparable to those made with current blocks.

What makes this invention different from previous designs is that whileit uses the previous mass produced concrete block design of 16″×8″×8″the special blocks are enlarged to 24″×16″×8″ and their cavities arefilled with reprocessed rubber tires cut into crumbs. This larger blockproduces an exceptionally high resistance to heat transmission throughthe final wall application. The end result is that walls designed bythis method will have high heat sustainability and consequently willrequire reduced heat usage to heat and cool the structure, resulting infewer emissions of the greenhouse gases responsible for climate changeand lower costs for the inhabitants.

Structures built with this design will be more rigidly stable, moreresistant to hurricane, tornado, and high winds, and seaside salt spray,increased fire protection, more durable, more insect and vermin proof,and quieter for users of the structure. In addition, the blocks willutilize rubber crumb made from new and recycled scrap vehicle tires.Scrap tires are a difficult and expensive to manage and environmentallyharmful waste product.

SUMMARY OF THE INVENTION

This invention comprises three parts:

Part 1—Design and Fabrication of the Special Cement Blocks

The special blocks will measure 24″×16″×8″, sixteen inches deeper thantypical cement blocks. They will be cast in special molds in a modifiedblock-making machine. Wall dimensions of special blocks will be similarto walls made with 16″×8″×8″ blocks, although they will be 24″ thick(c). The height will remain at 8″ (b). (FIGS. 1, 2, 4, and 10).

Part 2—Manufacture of Rubber Crumb

Rubber crumb (7) is the name given to any material resulting fromgranulating scrap rubber tires or other rubber into uniform granuleswith the steel, fiber, dust, glass, and rock removed. Most of thismaterial will come from companies that process scrap tires fromlandfills or from tire replacement businesses. Historically, scrap tireshave been difficult and expensive to manage and their disposal hascaused environmental harm. Processing scrap tires into rubber crumb foruse as wall insulation material will reduce these challenges.

Part 3—Installation of Special Cement Blocks (2) and Addition of CrumbRubber (7)

The special cement blocks will be placed on a concrete foundation (1) bya mason with mortar (3) between each block to form a mortar joint. Thiswill be the first course of the block wall. Conduits (4) will beinstalled in the block cavities for electrical, plumbing, and relatedneeds (FIG. 2). Rubber crumb (7) will be added to the block cavities toa depth level with the top edge of the blocks. Mechanical or physicalmeans (9)(10) with concrete vibrator (9), flex hose (10), and blower(11) will be utilized to eliminate air pockets (FIG. 3). The successivecourses of the blocks with conduits and crumbs will be staggered by 8″(d) and continued until the desired wall height is attained (FIG. 3). Toachieve this alternating pattern with the 8″ overlap (d) in the corners,our special 24″ block will be rotated 90 degrees, alternating between16″ and 24″ as each course of the blocks is laid (FIG. 4). The result isa 24″ thick wall (c) throughout the structure.

All block dimensions must be multiples of 8″ to achieve maximum designefficiency. Going smaller on the 16″ block width (a) not only deviatesfrom the present wall procedure, but also results in the need foradditional blocks and increased labor cost to install them. Going largerthan 24″ (c) results in additional weight, which can become unwieldy fora single mason and would likely result in a two-mason operation at addedcost (FIG. 1).

To accomplish the increased thermal mass of the structure and resultinghigh R value, the overall width and length of the structure will beincreased by 32″. The additional material and labor cost to build thislarger structure will be quickly recovered through the reduced heatingand cooling costs of the finished building.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1—General Description of the Special Block

FIG. 2—Wall Construction Without Insulation

FIG. 3—Addition of Rubber Insulation

FIG. 4—Corner Wall Construction

FIG. 5—Surface Application-Layers of Stucco on Concrete Blocks

FIG. 6—Surface Application-Layers of Textured Acrylic Finish (TAF) onConcrete Blocks

FIG. 7—Surface Application-Brick Veneer on Concrete Blocks

FIG. 8—Surface Application-Various Siding on Concrete Blocks

FIG. 9—Hurricane and Tornado Proof Building Construction

FIG. 10—Detail Drawing of Special Block

FIG. 11—Detail Drawing of Special Block with Crumb Rubber

FIG. 12—Technique for Locating Reinforcing Rods in Foundation forInsulated Masonry System

FIG. 13—Installation of Reinforcement Rods in an Insulated MasonrySystem

FIG. 14—Installation of Modified USP 2″×8″ Joist Hanger on SpecialCement Blocks

REFERENCED DIMENSIONS

a-Nominal Dim=16″ (Actual 15.63″)

b-Nominal Dim=8″ (Actual 7.63″)

c-Nominal Dim=24″ (Actual 23.63″)

d-8″ Overlap

Typically, the interior wall finish is gypsum wallboard. To attach thewallboard to the special blocks the wallboard installer places a vaporbarrier (plastic film) against the inside surface of the blocks. Furringstrips are attached with screws to the film and blocks and the wallboardis then glued or screwed to the furring strips.

Different finishes go on to the foundation walls (1) and the course ofthe building above. The concrete blocks of the foundation and the blocksexposed above ground need to be covered by a material with high impactresistance to avoid damage from landscaping and other equipment.Installers typically use wire mesh covered by a layer of stucco orstucco-like coatings that do not require the mesh.

The most widely used exterior finishes include:

-   -   a) FIG. 5 describes stucco on concrete blocks utilizing brown        coat (12), scratch coat (13), lath (14), and finish coat (15).    -   b) FIG. 6 describes layers of textured acrylic finish (TAF) on        concrete blocks utilizing top coat (16), base coat (17),        fiberglass mesh (18), and color coat (19).    -   c) FIG. 7 describes brick veneer on concrete blocks utilizing        brick (20), on ledge (21), and finishing (22).    -   d) FIG. 8 describes vinyl, beveled wood, fiber-cement,        photovoltaic siding, and hardboard wood shakes and shingles        which utilizes shingles (23) and tar paper (24). Wood sheathing        (6) next to the concrete block is glued to the block and acts as        a vehicle to staple, nail, or screw siding (23) to during        installation. Also, to install necessary photovoltaic siding        wiring, a space is provided between sheathing to utilize tubing        (31) for wiring.

Further increases in R-value can be accomplished by the addition ofoutsulation (EIFS) cadding systems by Dryvit.

An additional feature of our special wall installation (FIG. 9) is theuse of USPHW with heavy-duty welded joist brackets (8), which can beslipped in while he walls are erected (FIG. 14). This simplifies theinstallation of the floor joists (27) in buildings (FIG. 9). Also shownis the ease of installing hurricane straps (26), and roof connectors(25) on roof frame (29) to protect structures from hurricane and tornadodamage on insulated concrete masonry systems (28).

Also, to achieve maximum insulated concrete masonry system strength forextreme weather-related conditions, steel reinforcement rods (30) can beadded (FIGS. 12 and 13). Layout of reinforcement rods can be simplifiedby the use of wooden templates (5) (FIG. 12).

I claim:
 1. A special 24″×16″×8″ concrete block with actual dimensionsof 151/2″×71/2″×231/2″ having four smooth sides that can be rotated toproduce a smooth sided corner arrangement with alternating joints forwall construction.
 2. A special 24″×16×8″ concrete block withadmixtures, pigments, or glazers added to give blocks increasedcompressive strength, decorative effect, or provide protection againstdeterioration.
 3. A special 24″×16″×8″ concrete block with internalslots for reinforcement rod insertion when utilized in residential,institutional, religious, commercial, and industrial buildingconstruction to further increase structural strength in earthquake andother severe calamity areas.
 4. Rubber crumbs obtained from chopped andgranulated new and recycled and recycled tires inserted by air pressureand agitation into hollow block cavities, during construction.
 5. Blocksto be offset by 8″ as each row is formed during construction.
 6. Blocksto be permanently secured together with mortar premix (comprised of ablend of portland cement, lime and masonry sand) per present cement typeconstruction.
 7. Blocks to be positioned so that the 16″ face is exposedto outside wall surface per present block construction. Exception is atcorners where alternate 16″ and 8″ surfaces are exposed.
 8. Blocks to bepositioned to obtain a 24″ thickness of wall, resulting in maximumstructural strength and thermal resistance.
 9. Outside surface of wallconstruction modified to include coatings, brick veneer and sidings,including photovoltaic sidings.
 10. To simplify and increase buildingconstruction strength, steel joist hangers are attached to specialblocks during construction to support floor joists.
 11. To resisthurricane, tornado, and other weather related conditions, hurricanestraps and roof connectors are attached to special blocks to furtherincrease building strength.